Disassembling and assembling transmission

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Hector Logan
5 years ago
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1 Disassembling and assembling transmission Preceding work: Removing and installing transmission with torque converter (27-600). Operation number of operation texts and operation values or standard texts and flat rates P Control pressure cable (98) Transmission (1) Oil sump (3) slacken lock with screwdriver, detach, attach (step 141). clamp on assembly pedestal and mounting plate remove, install. Bolts 8 Nm. Oil filter (5) Control valve body (2) Detent spring (142) and bracket (141) Bottom cover (13) with intermediate plate (14) and oil pipe (9) remove, install. Bolts 4 Nm. remove, install, 8 Nm. Pay attention to different bolt length. detach with bolt (140), fit on, 8 Nm. remove, install. Bolts (18), 8 Nm. Lift off complete. When assembling, check stop of resilient linkage ( mm) (step 137).

2 One-way valve (49), brake band guide B2 (101), locating pin (135), oil deflector piece (119), temperature inductor (117) remove, insert (step 131). Brake band piston B2 (15) remove by taking off locking ring (23). When installing, adjust play "L" of mm with thrust pin (26) (step 130). Brake band piston B1 (37) remove with assembly device , install. Take off locking ring (41), cover (40) and return springs (35, 36). When installing, adjust play "L" mm (steps 119 through 124). Measuring device , check lip sealing ring (39). Brake band guide B1 (34) remove, insert (step 81). Thrust body of thrust bearing B1 (31) remove, install by unscrewing screw plug (33) or transmission overload protection switch (33b), screwing on, 70 Nm. Check O-rings (32). Starter lockout switch (53) Take off by unscrewing bolts (55), 8 Nm. When installing, fix in place (step 146). Vacuum unit (60) detach with retaining plate, fit on, 8 Nm. Remove modulating pressure control valve (59) and thermal expansion pin (59a) and insert. P Kickdown solenoid valve (61) Joint flange (64) Washer (65) Rear transmission cover (70) Oil pipe (102) for mechanical speedometer drive unscrew, screw on, 20 Nm. remove, install by slackening twelve-side nut (62), 120 Nm, and locking (steps 113, 114). Wrench socket remove. unscrew bolts (71), screw on, 13 Nm. After this, detach cover by light hammer blows, lift off and disassemble (27-440). take off, fit on.

3 Parking lock gear (73), parking lock ratchet (74) and spreader spring (75) Shim (77) Plastic guide (80) and roller (81) take off, fit on. calculate thickness by measuring end play of output shaft (step 107). base measuring sleeve remove, fit on. Resilient linkage with detent plate (82) unscrew hexagon socket bolt (82a), screw in, then withdraw range selector lever (52) and withdraw detent plate (82) (step 31). Locking ring (123), helical gear (78) and locking ring (116) detach, attach (steps 87-89). Secondary pump (20) remove, install. Bolts (45) 8 Nm. Take off O-ring (18) and intermediate plate (19). Locking ring (47), cover (46) take off. Locking ring (43) compress with pliers and withdraw centrifugal governor, insert (step 91). P Front transmission cover (10) remove, install complete. Bolts (18) 13 Nm, disassemble (27-630), pay attention to Teflon rings. Before installing, measure end play "B" for clutch K1 and adjust mm (see step 82). Then, insert shim (95), thrust washer (96) and axial bearing into clutch K1.

4 Gear set (86-87) Brake band B1 (30) and clutch K1 (83) remove complete. When installing, adjust play "L"= mm of multi-disc brake B3 (step 75) by inserting discs (104, 105) and Belleville spring washer (85) (step 75). remove with gear set, install (see steps 76-79). Damping spring (134) remove, insert (step 72). Thrust pin (28) remove, install (step 126). Clutch K2 (100) withdraw, when installing fit onto gear set and push in together with gear set (steps 67, 68). Brake band B2 (27) remove, install by compressing brake band as far as possible (step 66). Thrust washer (113) remove, insert (step 64). Thrust body B2 (29) withdraw, check and insert with strap facing up (step 63). Supporting flange (79) remove, install. Bolts (114), 11 Nm. Stick Teflon rings (115) into the groove with grease (steps 59-61). Guide ring (88a) and lip sealing ring (88) check, renew if necessary. Make insertion mandrel in shop (step 54). O-rings (91, 92), sealing rings (92) and aluminium sealing rings (90) check, renew if necessary (steps 55-58). Adjusting data mm End play clutch K1 rear housing not fitted rear housing fitted End play clutch K Play of multi-disc brake B Play of brake band B Play of brake band B Play between linkage stop and locking piston Dimensions Plastic clip of resilient linkage Shims of axial bearing K Shims of helical gear/parking lock gear Thrust pin of brake band piston B mm steps Shims of thrust pin brake band piston B1 0.5, 1.0 and 1.5

5 Thrust pin of brake band piston B Sequence of discs LB3 08/88 Transmission P Transmission P Disc order effective 09/88 P B Disc versions Designation Item No. Thickness in mm Internally toothed discs Externally toothed discs optionally for compensating play 2.5 1) ) 2) ) 2) ) Compensating discs 5 optionally for compensating play Belleville spring washer 7 Tightening torques Nm Bolts of supporting flange K2 M 6B22 11

Hexagon socket bolt of detent plate M 6B20

Hexagon socket bolt of oil pipe M 6B15 8

Bolts of front cover M 8B40 13 Screw plug

nut for joint flange 120 Kickdown solenoid

6B55 Bolts of oil filter M 5B12 4 Bolts of

Special tools Lubricants For Teflon rings

Universal grease (refer to Service Product

Transmission Fluid (ATF) (refer to Service

6 Hexagon socket bolt of detent plate M 6B20 8 Bolt of leaf spring M 6B18 8 Bolts of starter lockout switch M 6B15 8 Hexagon socket bolts of secondary pump M 6B40 8 Hexagon socket bolt of oil pipe M 6B15 8 Bolts of rear housing M 8B35 13 M 8B80 Bolts of front cover M 8B40 13 Screw plug of thrust bearing B1 70 Twelve-side collar nut for joint flange 120 Kickdown solenoid valve 20 Hexagon socket bolts of vacuum unit M 6B15 8 Screw-and-washer assy. of bottom cover M 6B30 8 Bolts for strengthening plate of bottom cover 4 Bolts of control valve body M 6B50 8 M 6B55 Bolts of oil filter M 5B12 4 Bolts of oil sump M 8B30 7 Screw plug of test connection 13 1) Disc version effective 09/88. 2) Disc version up to 09/88. Special tools Lubricants For Teflon rings For sliding surfaces and bearing points Universal grease (refer to Service Product Specifications Sheet 267) Automatic Transmission Fluid (ATF) (refer to Service Product Specifications Sheets 236.4, 236.6, 236.7) Shop-made tool Impact mandrel see ill. step 54, note

7 Note When performing assembly work, the sealing surface of the cast oil distributor plate in the transmission housing must be treated with care. In addition, ensure scrupulous cleanliness. Proper operation of the transmission depends on there not being any dirt on the transmission parts and in the oil circuit. For this reason, after disassembling, remove the gasket residues, wash all parts thoroughly, flush through oil passages and blow out with compressed air. Rubber gaskets must not come into contact with washing petroleum as this may attack the rubber. Use methylated spirits as a cleaner for rubber parts. Ensure also that the parts do not come into contact with fluffing rags for fluffs sticking to the parts can cause operating faults. Disassembly Remove control pressure cable by pressing strap (arrow) toward the sleeve (111), turning 90 counter-clockwise and withdrawing up the way. Detach connecting rod. P Transmission with selector programme: Use a screwdriver to release lock (arrow). P

8 3 Bolt mounting plate (071) to the assembly pedestal (070) Insert transmission into mounting plate and fix with the bolt (arrow). Note If a stiffener rib is touching the recess of the retaining pin, rework retaining pin slightly. P Unscrew bolts (4) and take off oil sump (3). P Remove screws (6) and take off oil filter (5). P Unscrew bolts (7) and take off control valve body (A). Disassemble and assemble control valve body (27-400). P

9 7 Unscrew bolts (140). Take off bracket (141) together with detent spring (142). 8 Unscrew bolts, lift off bottom cover (13) together with intermediate plate (14) and oil pipe (9). Disassemble bottom cover (27-430). P Remove one-way valve (49), brake band guide B2 (101), locating pin (135), temperature inductor (117) and oil deflector piece (119). Note The additional inductor (arrow) was only installed in the case of repairs. P A 10 Press in brake band piston cover B2 (17) and remove locking ring (23). 11 Take off brake band piston cover. P Withdraw brake band piston B2 (15) with thrust pin (26) clipped in place. P

10 13 Fit on assembly device (026) , bolt to the transmission housing and tension. 14 Take out locking ring (41). P Release tension on assembly device (026), take off brake band piston B1 (37) and also cover (4) and return springs (35, 36). 16 Unscrew assembly device (026). P Withdraw brake band guide B1 (34). P Remove screw plug (33) for pressure body B1. Note On transmission first of all remove the transmission protection switch with oil pipe. 19 Unscrew hexagon socket bolts (58), take off retaining plate (57) and vacuum unit (16) together with thrust pin. 20 Unscrew bolt (55) and take off starter lockout switch. P

11 21 Take out pressure body B1 (31) and modulating pressure control valve (59). P Unscrew kickdown solenoid valve (61). 23 Engage parking lock. Unscrew twelve-side collar nut (62) and pull off joint flange (64). Wrench socket P Note On vehicles with transmission shift point retard, unscrew shift point retard 2! 3 switchover valve (Y3/2), oil sump drain (0) and test connection (MR). P Take off washer (65). 25 Unscrew bolts (71). 26 Detach rear cover (70) by slight blows with a plastic-headed hammer and take off. 27 Disassemble rear cover (27-450). P

12 28 On vehicles with electronic speedometer, take off parking lock gear (73) with rotor, parking lock ratchet (74) and spreader spring (75). P On vehicles with mechanical speedometer, take off oil pipe (102), parking lock gear (73) with helical gear, parking lock ratchet (74) and spreader spring (75). P Pull off plastic guide (80) up the way, then take off roller (81). P Unscrew hexagon socket bolt (82a), withdraw shaft (76) and take out detent plate (82) together with resilient linkage. P

13 32 Take snap ring (123) off the input shaft (68) and take out helical gear. Locking pliers P Take locking ring (116) off the input shaft (68). Unscrew bolt (87) and take out oil pipe (arrow). Note Oil pipe (arrow) is no longer fitted effective July P Unscrew hexagon socket bolts (45) and take off secondary pump (20). P Take off O-ring (18) and intermediate plate (19) of the secondary pump. P

14 36 Press in locking ring (46) and take out locking ring (47). 37 Withdraw cover (46). P Compress locking ring (43) and take out centrifugal governor (50). P Unscrew bolts. 40 Screw two bolts into the tapped holes (arrows) and withdraw the front cover (10) on them. a Do not press off the cover with the two bolts. If necessary, detach cover with a screwdriver. P Grip gear set at the input shaft (87) and carefully withdraw to the front. 42 Pull clutch K1 (83) with brake band B1 (30) off the gear set. 43 Take off discs of B3 (arrow). P

15 44 Take out damping spring (134). P Take thrust pin out of the brake band (27). 46 Take out clutch K2 (100). Disassemble clutch K2, assemble and measure (27-690). P Take off thrust washer (113). P Unscrew bolts (114). Screw in opposite two bolts approx. 80 mm long. Detach supporting flange (79) from the housing by hammer blows on the two bolts. P

16 49 Position brake band B2 (27) at an angle, compress and take out. Note Transverse cracks in the brake band lining B2 are not a cause for concern. 50 Withdraw pressure body B2 (29). 51 Remove the sealing rings, test connection plugs etc. still remaining in the housing. P

Dismantling and assembling transmission

27-640 Dismantling and assembling transmission Operation number of the operation texts and work units or standard texts and flat rates: 27-4010 P27-5367-61 Control pressure cable (98) Slacken, remove and